Shutter assembly

Abstract

A shutter assembly includes a stile having a solid core and a plastic outer cover. Holes are formed in the plastic outer cover and aligned with an axial groove formed in the solid core to receive a slotted louver pin. The louver pin includes a pair of arms that provide a sufficient compression fit in the axial groove of the stile while enabling each louver to rotate freely. Separate stile end caps are formed to be flush with the edges of the ends of the plastic cover. Each louver includes louver edges and opposite end caps which are substantially flush with the louver edges. A method of manufacturing a shutter assembly is also provided.

1. A shutter assembly comprising:
 a stile defining a longitudinal axis and including a cover and an inner core, the inner core including an axial groove extending parallel to the longitudinal axis of the stile, wherein said axial groove has a width and a length, said length being greater than said width; 
 a louver rotatably coupled to the stile, the louver having a louver body and a louver end cap, the louver end cap comprising an outer planar surface extending in a direction generally perpendicular to a longitudinal axis of said louver body, the louver body defining a louver end surface extending in a plane which is generally co-planer with said louver end cap outer planar surface, wherein the louver end cap has a slotted compressible louver pin extending therefrom, said louver pin being received in the axial groove of the inner core of the stile, wherein at least distal ends of a pair of arms of the louver pin remain compressed by sidewalls of the axial groove to provide friction between the pair of arms and the axial groove to hold the louver in place relative to said stile. 
 
     
     
       2. The assembly of  claim 1 , further comprising:
 a stile end cap having an outward facing stile planar surface and a lip, said lip being supported by a shoulder of the stile. 
 
     
     
       3. The assembly of  claim 1 , wherein the inner core of the stile is composed of wood. 
     
     
       4. The assembly of  claim 1 , wherein the cover defines a plurality of apertures open to the axial groove. 
     
     
       5. The assembly of  claim 1 , wherein the width of the axial groove is uniform throughout the length of the axial groove. 
     
     
       6. A shutter assembly, comprising:
 a stile defining a longitudinal axis and including a plastic cover and an inner wood core, the inner wood core including an axial groove extending parallel to the longitudinal axis of the stile, wherein said axial groove has a width and a length, said length being greater than said width, the cover comprising a planar longitudinal section that faces the axial groove of the inner wood core, the planar longitudinal section defining at least one aperture open to the axial groove; 
 a louver rotatably coupled to the stile, the louver having a louver body and a louver end cap, the louver end cap comprising an outer planar surface extending in a direction generally perpendicular to a longitudinal axis of said louver body, the louver body defining a louver end surface extending in a plane which is generally coplanar with said louver end cap outer planer surface, wherein the louver end cap has a slotted compressible louver pin extending therefrom, said louver pin being received in the axial groove of the inner core of the stile, wherein at least distal ends of a pair of arms of the louver pin remain compressed by sidewalls of the axial groove to provide friction between the pair of arms and the axial groove to hold the louver in place relative to said stile. 
 
     
     
       7. The assembly of  claim 6 , further comprising:
 a stile end cap having an outward facing stile planar surface and a lip, said lip being supported by a shoulder of the stile. 
 
     
     
       8. The assembly of  claim 6 , wherein the cover defines a plurality of apertures open to the axial groove. 
     
     
       9. The assembly of  claim 6 , wherein the width of the axial groove is uniform through the length of the axial groove.